Spring cushion unit and method of making



G. A. STACKHQUSE SPRING CUSHION UNIT AND METHOD OF MAKING Jufly 26, 1%.

Filed Nov. 18, 1955 s Sheets-Sheet 1 INVENT OR.

6 6 U o h K C .m An Wm V w Cu ATTORNEYS,

I My .26, m G. A. sTAcKHousE SPRING CUSHION UNIT AND METHOD OF MAKING 3 Sheets-Sheet 2 Filed NOV. 18,- 1935 INVENTOR. GfiOYQZ Atackhousa I ATTORNEYS.

July 26, 193%,

STACKHOUSE SPRING CUSHION UNIT AND METHOD OFMAKING s Sheets-Shet 3 Filed NOV. 18, 1935 ATTORNEYS Patented July 26, 1938 "J 5 PATENT OFFICE SPRING CUSHION UNIT AND DIETHOD OF MAKING- George A. Stackhouse, Oakland, Calif., assignor to L. A. Young Spring and Wire Corporation,

Detroit, Mich- Application November 18, 1935, Serial No. 50,303

2 Claims.

This invention relates to improvements in spring cushion units and method of making.

The main objects of this invention are:

First, to provide a spring cushion unit or 5 structure which is well adapted as a filler for mattresses, pillows and cushions or of spring units or toppers for seat cushions, automobile upholstery and the like.

Second, to provide a structure having these advantages which is provided with a base or foundation padding for the upholstery, this padding being-effectively secured to the filler unit so that it is not likely to be displaced in assembling the unit in the completed structure or in use.

Third, to provide a structure in which the springs are individually supported and pocketed, at the same time a structure which is very economical in material and assembly.

Fourth, to provide a structure of the pocketed spring type in which springs of relatively large diameter relative to their height may be used.

Fifth, to provide a method of producing spring units having these advantages.

Objects relating to details and economies of my invention will appear from the description to follow. The invention is defined and pointed out in the claims.

Preferred embodiments of my invention are illustrated in the accompanying drawings, in which:

Fig. l is a fragmentary plan View of a cushion unit embodying the features of my invention, a portion of the upper wall and of the padding being removed to better illustrate the construction and relation of parts. i

Fig. 2 is an enlarged detail section on line 22 of Fig. l, the springs bein'gindicated in fulllines, certain of the parts being shown conventionally, no attempt being made to section the fabric or the padding.

Fig. 3 is a fragmentary plan view of one of the pocket units.

Fig. 4 is a fragmentary plan view of a modified form of pocket unit, the modification being in the connecting tape or strip for the pocket members.

Fig. 5 is a fragmentary perspective view of one of the pocket members.

Fig. 6 is a diagrammatic view of the preferred form or method of stitching.

Fig. 7 is a fragmentary conventionalized perspective view of one of the casing walls with the padding thereon.

Fig. 8 is an enlarged detail view illustrating the preferred method of preliminary attachment of the padding to the wall fabric.

Fig. 9 is a fragmentary plan view of a modified form or embodiment of my invention in which wire staples or stitches are employed in 5 lieu of the threads of the sewing machine stitchmg.

Fig. 10 is an enlarged detail section on a line corresponding to line I0I0 of Fig. 9.

Fig. 11 is an enlarged detail view on a line l0 corresponding to line llll of Fig. 10.

My improved spring cushion as illustrated in the accompanying drawings comprises topand bottom walls I and 2, the edges of which are turned inwardly and stitched together at 3 to 15 provide the side walls 4 of the casing. It will be understood that top and bottom are here used as a matter of convenience in description in both the specification and claims as the structure is the same on both sides and may be used either side up. In the preferred embodiment illustrated these walls are formed of burlap which is found to be suitable in strength and also has a relatively coarse mesh which facilitates the preliminary attachment of the padding 5 there-'25 to. This padding 5 is preferably of sisal although other fibrous material may be used, tufts of sisal indicated at 6 being drawn through the burlapthat is, drawn between strands thereof at suitably spaced intervals thus effecting a .preliminary attachment of the padding to the easing walls so that they may be conveniently handled in the assembling operations.

I provide a plurality of pocket units, each consisting of pocket members I also preferably formed of burlap, the ends of the pocket mem- I bers being folded upon themselves and secured by stitching 8. This greatly adds to the strength of the pocket members and prevents their. raveling or pulling out when attached to the side walls 40 as will be hereinafter described. These pocket members are secured together in seriesby means of a longitudinal strap or tape 9 which, in the preferred embodiment, is also a strip of burlap, this being secured by the longitudinal row of stitches III. In the embodiment illustrated in Fig. 4, the longitudinal strip is in the form of a tape ll secured, however, by the row of longitudinal stitches Hi. This connecting of the pocket members performs a double function of securing them in properly spaced relation for assembly in the casing and also to provide guiding throats or means from one pocket to another or a row of pockets, thereby facilitating the introduction of the springs. The pocket units can to another as indicated in'Fig. 6. This stitching passes not only through the infolded ends of the pocket members and the casing walls but through the padding, thus permanently securing the padding to the wall and effectively quilting the same-that is, providing a quilt stitching that holds the fibers in their arranged position'or prevents the objectionable displacement thereof .in, use or in the handling and assembling of the unit in a mattress or other cushion structure, the pocket units being arranged in zig-zag spaced relation with their pockets zig-zagged, as stated, providing rows of spring pockets, the pockets of adjacent rows alternating and the pockets of each row connected by central longitudinal passages throughwhich springs may be introduced into the pockets. The passages being central of the pockets permit the walls being distended to allow the introduction of springs of greater diameter than would be possible if the pocket openings were in the sides of the pockets. After the springs are inserted, the side walls of thecasing which have been left open for the introduction of springs are closed, thus completing the unit.

With this arrangement, a minimum amount of material is required for forming the pockets. The structure may be rapidly assembled not only in the matter of assembling the fabric parts but the introduction of the springs.

Inthe embodiment shown in Figs. 9, 10 and 11, metal fasteners or stitches I3 are employed instead of the threadsor rows of stitches of the embodiment described. These fasteners or wire stitches also serve to secure the padding simultaneously withthe securing. of the pocket members.

The pocket members and the casing walls may be very easily and quickly assembled to receive the springs and when padding is employed, this is effectively secured tothe casing walls and quilted in the same operation.

My improved cushion structure is very economical in material and may be very easily assembled.

I have illustrated and described my improvements in highly satisfactory embodimentsthereof. I have not attempted to illustrate or describe certain adaptations or embodiments which I contemplate as it isbelieved that this disclosure will enable those skilled in the art to embody or adapt my improvements as may be desired.

gaging 'tufts'of the pad fibers between strands of l the burlap, a plurality'of pocket units disposed in spaced diagonal relation within the casing and each comprising a. plurality of pocket members of burlap; connected in spaced relation by strips disposed centrally across the same and stitched thereto, said pocket members having their ends folded upon themselves and stitched in folded relation, the pocket members of the units being arranged in zig-zagged relation and their folded ends being stitched to the top and bottom casing.

wallsby continuous zig-zagged rows of stitches through the casing walls and padding thereon whereby a plurality of rows of spring pockets are provided with the pockets of adjacent rows in alternating relation, the pocket units being so spaced relative to each other as to provide a central longitudinal passage for each roW of pockets through which springs may be introduced into the pockets, the said pocket unit attaching stitching constituting quilting and securing means for the padding, and springs arranged in said pockets, the individual springs being separated by said pocket membersand said strips.

2. A spring cushion structure comprising top, bottom and side casing walls of burlap having padsof sisal arranged on the outer sides thereof and attached thereto at spaced intervals by engaging tufts of the pad fibersbetween strands of the burlap, a plurality of pocket units disposedv in spaceddiagonal relation Within the casing and each comprising a plurality of pocket members of burlap connected in spaced relation by strips disposed centrally across the same and stitched thereto, the pocket members of the units being arranged in zig-zagged relation and their ends being stitched to .the top and bottom casing walls by stitches through the casing walls and padding thereon whereby a plurality of rows of spring pockets are provided with the pockets of adjacent rows in alternating relation, the pocket units being so spaced relative to eachother as to provide a'central longitudinal passage for each row of GEORGE 'A. STACKHOUSE. 

